Heterogeneous catalysts for olefin epoxidation

ABSTRACT

SOLID CHEMICAL COMBINATION OF CERTAIN METAL OXIDES OR HYDDROXIDES WITH OXYGEN COMPOUNDS OF SILICON GIVE IMPROVED PERFOAMANCE AS A CATALYST FOR THE EPOXIDATION OF OLEFINICALLY UNSATURATED COMPOUNDS WITH ORGANIC HYDROPEROXIDES WHEN THE CATALYSTS ARE FIRST TREATED WITH AN ORGANIC SILYLATING AGENT AT ELEVATED TEMPERATURE.

United States Patent U.S. Cl. 252-430 24 Claims ABSTRACT OF THE DISCLOSURE Solid chemical combinations of certain metal oxides or hydroxides with oxygen compounds of silicon give improved performance as catalysts for the epoxidation of olefinically unsaturated compounds with organic hydroperoxides when the catalysts are first treated with an organic silylating agent at elevated temperature.

This application is a continuation-in-part of applicants copending application Ser. No. 77,385, filed Oct. 1, 1970, now abandoned.

BACKGROUND OF THE INVENTION Field of the Invention This invention relates to improvements in metal oxide or hydroxide-siliceous solid materials and the use of these improved materials as catalysts for the epoxidation of olefins with organic hydroperoxides.

The Prior Art In copending U.S. patent application Ser. Nos. 812,922 filed Apr. 2, 1969 (now U.S. 3,634,464) and 812,924, filed Apr. 2, 1969 now abandoned and 173,325 and 173,326, filed Aug. 19, 1971 by H. P. Wullf and F. Wattimena, and now-abandoned applications Ser. Nos. 812,920 and 812,923, filed Apr. 2, 1969 by Wulff and Wattirnena and Serial No. 868,584, filed Oct. 22, 1969 by Wattimena, it is shown that certain metal oxides and hydroxides, for example, the oxides and hydroxides of titanium, molybdenum, vanadium, zirconium and boron, when chemically combined With inorganic siliceous oxides, for example silica, are effective heterogeneous catalysts for the reaction of olefins with organic hydroperoxides to form olefin oxides. In such an olefin epoxidation reaction, an olefin is mixed with an organic hydroperoxide and passed over the metal oxide siliceous oxide catalyst. Ideally, the catalyst should cause the hydroperoxide to react exclusively with olefin to produce only olefin oxide. In other words, the catalysts should be 100% selective to the olefin epoxidation reaction. In fact, as with virtually all heterogeneously catalyzed reactions, only a substantial proportion, and not all of the hydroperoxide which reacts, reacts with olefin to form olefin epoxide in the presence of these known catalysts. The remainder of the reacting hydroperoxide forms less desirable by-products. Because of the well-known high reactivity of hydroperoxides and the general tendency of peroxides to decompose to non-desired products in the presence of a great number of catalyst materials, the search for ways to improve the selectivity of heterogeneous catalysts for epoxidation of olefins with organic hydroperoxides is especially important and also especially difficult.

STATEMENT OF THE INVENTION It has now been found that olefin expoxidation catalysts comprising an inorganic oxygen compound of silicon in chemical combination with certain metal oxides or hydroxides are improved and catalyze the epoxidation reaction of olefim'cally unsaturated hydrocarbons with organic hydroperoxides to give olefin oxides with improved efliciency when these catalysts are treated prior to use by contact with an organic silylating agent at elevated temperatures.

More especially, it has been found that processes for preparing olefin oxides by reacting olefins with organic hydroperoxides in the presence of metal oxide-siliceous solid heterogeneous catalysts at temperatures of from 25 C. to 200 C. are improved when the catalysts are contacted with an organic silylating agent at temperatures of up to about 450 C. prior to use. In a particularly preferred embodiment of the invention, contacting metal oxide silica materials (such as titania-silica) with an organic silylating agent (such as an organic halosilane or an organic silazane) at temperatures of from C. to 450 C. makes the resulting materials better, more efficient, and more selective catalysts for the epoxidation of olefins with organic hydroperoxides.

DETAILED DESCRIPTION OF THE INVENTION The Catalysts Treated The catalysts which are improved by silylation in accordance with the invention are olefin epoxidation catalysts consisting essentially of a solid inorganic oxygen compound of silicon in chemical combination with at least about 0.1% by weight of an oxide or hydroxide of titanium, molybdenum, vanadium, zirconium or boron. These metal oxide-hydroxide/siliceous oxide composites and methods for their preparation are described in the above-listed U.S. applications Ser. Nos. 812,920, 812,923, 812,924, 868,584, now abandoned, and 812,922, now U.S. 3,634,464, the disclosures whereof are incorporated herein by reference. The oxygen compound of silicon employed is a siliceous solid containing a major proportion of silica. In general the siliceous solids are further characterized by having a specific surface area of at least 1 m. /g. and preferably having an average specific surface area of from 25 mF/g. to 800 mF/g. Very suitable inorganic siliceous solids are the synthetic porous silicas such as silica gels, formed by flocculating particles of amorphous silica, and the fumed silicas. Preferred siliceous solids contain at least about 99% w. silica.

Chemically combined with the siliceous solid, in catalysts improved by the process of the invention, is a metal oxide or hydroxide. Suitable metal oxides or hydroxides include those of titanium, vanadium, boron, molybdenum and zirconium.

Generally, the catalysts contain from about 0.2% to 10% by weight (basis catalyst) of such metal oxides or hydroxides. Very suitable catalysts contain from 0.5% to 8% by weight of an oxide or hydroxide of titanium in chemical combination with silica.

A most preferred catalyst for treatment by this invention consists essentially of silica chemically combined with from 0.5 to 5% by weight of titanium oxide.

The catalyst compositions which are to be treated suitably incorporate non-interfering and/or catalyst promoting substances, especially those which are chemically inert to the reactants and products. The catalysts may incorporate minor amounts of promoters, for example, the alkali metals or alkaline earth metals as oxides or hydroxides. Alkali metal additions of from 0.01 to about 5% by weight (basis catalyst) are preferred as promoters.

An excellent catalyst for treating in accord with this invention consists essentially of silica chemically combined with from 0.5 to 5% by weight of titanium oxide and from 0.01 to 5% by weight of calcium (as the oxide) as promoter.

The catalyst compositions are prepared by a variety of methods including impregnation of a siliceous support with a suitable metal-containing solution followed by heating, cogelling the metal hydroxide and silica, and by calcining together a mixture of inorganic siliceous solid and metal oxides atelevated temperatures. The method of catalyst preparation is not critical to the functioning or etfectiveness of the present invention.

The Silylation Treatment In accordance with the invention, metal oxide-siliceous solid epoxidation catalysts as herein described are improved by treatment with an organic silylating agent at elevated temperatures. As is often the case in the field of heterogeneous catalysis the exact catalytic mechanism for epoxidation with these catalysts and the exact reason for their improvement with silylation are not known with certainty. It is recognized, however, that the silylation treatment imparts a hydrophobic character to the metal oxide/ silica catalysts. Also, it i known that the silylation agent reacts with active hydrogens, i.e., Brnsted acid sites on the catalyst surface, replacing them with organic-silicon groups.

Suitable silylating agents include the organosilanes, organosilylamines, and organosilazanes. One generally preferred class of silylating agents are the tetrasubstituted silanes having from 1 to 3 hydrocarbyl substituents, such as, for example, chlorotrimethylsilane, dichlorodimethylsilane, chlorobromodimethylsilane, nitrotrimethylsilane, chlorotriethylsilane, iododimethylbutylsilane and chlorodimethylphenylsilane. Very suitable silylating agents of this class comprise the tetrasubstituted silanes wherein at least one substituent is halogen selected from fluorine, chlorine, bromine and iodine and at least one substituent is hydrocarbyl of from 1 to 4 carbon atoms, that is, organohalosilanes. Preferred organohalosilane silylating agents are the tetrasubstituted silanes having from 1 to 3 halo substituents selected from chlorine, bromine and iodine with the remainder of substituents being methyls. Particularly preferred organohalosilane silylating agents are dichlorodimethylsilane and chlorotrimethylsilane with chlorotrimethylsilane being most preferred.

Another generally preferred class of silylating agents are the organosilazanes, particularly the organodisilazanes. These materials are represented by formula (I) the six Rs independently are organic groups or hydrogens. Preferably the organosilazanes contain Rs which independently are hydrogens or alkyl groups of up to about 8 carbon atoms. Because of their method of production, these organosilazanes are symmetrical. Such silazanes include for example:

1,2 diethyldisilazane, 1,1,2,2 tetramethyldisilazane, 1,1,1,2,2,2 hexamethyldisilazane, 1,l,2,2 tetraethyldisilazane, and 1,2 diisopropyldisilazane. Of the organosilazanes, those in accord with formula I containing 4 or 6 lower alkyl groups each of from 1 through 4 carbon atoms and or 2 hydrogens as their R groups are very preferred, with hexamethyldisilazane being the most preferred.

The two groups of preferred organic silylating agents each have advantages. The organohalosilane silylating agents are readily available and give excellent results under a variety of catalyst treatment conditions, although they pose a problem in that corrosive hydrogen halide is generated when they are used. The organosilazanes avoid the corrosion problem.

To effect the improving silylation, the metal oxide-silica chemical combination catalyst is contacted with a suitable silylating agent as herein defined, at elevated temperature. This may be accomplished in a variety of manners. For example, the catalyst particles may be mixed with a liquid silylating agent and then heated, or the catalyst particles may be heated and contacted with a stream of hot silylatmg agent vapor. The silylation may be carried out as a batch, semi-continuous or continuous process. Regardless of the method employed, best results are obtained with temperatures in the range of from about C., to about 450 C. with the organohalosilanes, temperatures of from about 300 C. to about 425 C. are preferred and temperatures of from about 375 C. to about 410 C. are most preferred as they tend to give the most selective catalyst products. With the organosilazanes, temperatures of from 100 C. to 300 C. are preferred and temperatures of from C. to 250 C. are most preferred.

The length of time required for the silylating agent to react with the catalyst surface depends in part on the temperature and agent employed. Lower temperatures require longer reaction times. Generally, times of from 0.1 to 48 hours are suitable. With the organohalosilanes, times of from 1 to 48 hours are typical. With these agents, at a temperature of 325 C., for example, times of from about 10 to 48 hours are preferred. At a temperature of 450 C., 1 to 5 hours is preferred. With the organosilazanes 0.1 to 5 hours is preferred.

The amount of silylating agent employed can vary widely. Amounts of silylating agent of from 1% by weight (basis the entire catalyst composition) to about 75% by weight are suitable with amounts of from 2% to 50% being preferred. The silylating agent can be applied to the catalyst either in one treatment or in a series of treatments. Generally a single treatment is preferred for reasons of operating economy.

It has been found that best results are often achieved by hydrating the metal/ silica catalyst before silylation. Hydration is effected by contacting the catalyst prior to silylation with water and then heating it or by contacting the catalyst with steam at elevated temperatures, such as temperatures above 100 C., preferably in the range of 150 C. to 450 C. for from about /2 to about 6 hours. When employing organosilazanes as silylating agents, best results are achieved when hydration is effected by steam ing at a temperature of 300450 C. for from about 1 to about 6 hours.

Epoxidation Catalysis The solid silica/metal oxide catalysts when treated according to the invention are especially suitable for use as heterogeneous catalysts in liquid phase processes for epoxidation of olefinically unsaturated hydrocarbons by reaction with hydrocarbon hydroperoxides. Their use in such processes represents a major improvement therein, since markedly higher selectivities to olefin epoxide are achieved with treated catalysts than are possible with untreated catalysts at identical reaction conditions.

As olefinic reactant in this reaction may be employed any hydrocarbon having at least one aliphatic olefinically unsaturated carbon-carbon double bond, generally containing from 2 to 30 carbon atoms but preferably from 3 to 20 carbon atoms.

Preferred as olefinic reactant are the linear alpha alkenes of from 3 to 10 carbons such as propylene, butene-l, pentene-l, octene-l and decene-l. Preferred hydrocarbon hydroperoxides are secondary and tertiary hydroperoxides of up to 15 carbon atoms, especially tertiary alkyl hydroperoxides such as tertiary 'butyl hydroperoxide; and aralkyl hydroperoxides wherein the hydroperoxy group is on a carbon atom attached directly to an aromatic ring, e.g., a-hydroperoxy-substituted aralkyl compounds such as a-methylbenzyl hydroperoxide and cumeme hydroperoxide.

In such an epoxidation process it is suitable to employ a molar ratio of olefinic reactant to hydroperoxide of at least 1:1 with ratios of from 2:1 to 20:1 being preferred.

The epoxidation reaction is conducted in the liquid phase in solvents or diluents which are liquid at reaction temperature and pressure and are substantially inert to the reactants and the products produced therefrom. Very suitable as solvents are hydrocarbons such as the hydrocarbon corresponding to the organic hydroperoxide, or

alternatively excess olefin. The reaction is conducted at moderate temperatures and pressures. Suitable reaction temperatures vary from about C. to about 200 C., but preferably from 25 C. to 150 C. The reaction is conducted at or above atmospheric pressure. The precise pressure is not critical so long as the reaction mixture is maintained substantially as liquid phase. Typical pressures vary from about 1 atmosphere to about 100 atmospheres.

The olefin epoxide products are recovered from the resulting reaction product mixture by conventional means, e.g., fractional distillation, extraction, fractional crystallization and chromatographic techniques.

The olefin oxide products of the epoxidation are materials of established utility and many are chemicals of commerce. For example, illustrative ole'fin oxides which are readily prepared by the process of the invention such as propylene oxide, 1,2-epoxybutane, 1,2-epoxy-2-methylpropane, 1,2-epoxydodecane and 1,2-epoxyhexadecane are formulated into useful polymers by polymerization or copolymerization as disclosed by U.S. Pat. 2,815,343, 2,871,219 and 2,987,489.

The invention will be further described with reference to the following examples. These are for illustrative purposes only and are not to be construed as limitations on the invention.

Example I A. A 300 g. sample of commercial silica gel having a surface area of 340 mF/g. and a pore volume of 1.15 cc./ g. (Davison I.D. grade 59 silica) was'contacted with a solution of 18 g. of titanium tetrachloride in 350 ml. of methanol. The impregnated silica gel was dried at a temperature of 100 C. and then calcined at a temperature of 800 C. for 2 hours to produce a titania/silica product. 250 Grams of this calcined material was then rehydrated by contact with water for 10 hours to increase the number of silanol (SiOH) groups on the catalyst surface. This catalyst was then contacted with 50 mls. of chlorotrimethylsilane as vapor for 15 hours at 325-350 C. The silylation was repeated twice. The catalyst preparation was repeated, without silylation. The resulting catalysts (both silylated and unsilylated) were compared. Analysis showed that each contained 1.5% by weight titanium. The silylated catalyst was hydrophobic while the unsilylated catalyst was hydrophilic.

B. The silylated and unsilylated tit-ania-silica products of part A were comparatively tested as olefin epoxidation catalysts. In each test a 1 gram sample of catalyst was contacted with 17 g. of octene-l and 28.6 g. of a 12% by weight solution of ethylbenzenehydroperoxide in ethylbenzene in a 100 ml. glass reactor. The reaction temperature was 100 C. and the reaction time was 1 hour. The results of these tests are given in Table I. The silylated catalyst..gave markedly higher selectivity to the desired epoxide-forming reaction.

C. The epoxidation of propylene with ethylbenzene hydroperoxide was conducted in a 0.43 inch internal diameter 20 inch long fixed bed tubular reactor packed with 20 grams of the silylated titania-silica of Part A. A reaction mixture consisting of 6 moles of propylene per mole of ethylbenzene hydroperoxide in ethylbenzene was continuously fed to the reactor at a liquid hourly space velocity (LHSV) of 2 cc.s per cc. of catalyst per hour (hereinafter hr.- The reactor was maintained at the indicated temperature and a pressure of 450 p.s.i.g. The reaction conditions and the analysis of the product mixture after the indicated cumulative operating time are provided in Table II. For purposes of comparison, the results of a similar test with an unsilylated 1.0% by weight titanium on silica catalyst additionally containing /2% by weight of calcium (prepared by the method of Example I) are provided in Table III.

TABLE I Hydroperoxide Epoxide conversion, selectivity, percent percent 5 Catalyst:

1. 5% Ti 86.0 81.7 Silylated 1.5% Ti 85. 6 94. 7

TABLE II 10 Continuous epoxidation with silylated catalyst Propylene Hydroperoxide oxide Temp, conversion, selectivity, 0. percent percent Cumulative hours: 83 80 97 92 85 97 95 88 96 92 623 93 97 91 TABLE I11 Continuous epoxidation with unsilylated catalyst Propylene Hydroperoxide oxide Temp conversion, selectivity, percent percent Cumulative hours:

Example II A. Two silylated titania-silica catalysts were prepared. First, two 350- gram batches of calcined, unsilylated, 1.5% by weight titanium catalyst were prepared as described in part A of Example I. Then, these materials were each rehydrated with water and contacted with 50 grams of chlorotrimethylsilane for 15 hours. The first catalyst (A) was silylated once at a temperature of 355-375 C. while the second catalyst (B) was silylated once at a temperature of 365390 C.

B. The silylated catalysts of part A were repeatedly tested as olefin epoxidation catalysts by the batch test described in part B of Example I, octene-l being epoxidized with ethylbenzenehydroperoxide. The results of these tests are given in Table IV.

C. Catalysts A and B were evaluated in the continuous propylene epoxidation reactor of Example I, Part C with the conditions and feeds of that Example. After 500 hours of operation, at 95 C. both catalysts A and B exhibited 95-96% propylene oxide selectivity at 9596% hydroperoxide conversion.

TABLE IV Hydroperoxide Epoxide conversion, selectivity, 5 5 percent percent Catalyst:

A (silylated at 355-375 C.) 95-96 91-92 B (silylated at 365390 C.) 97-98 93-94 Unsilylated- 94-96 79-81 ing calcination.

Example III A. A 40 g. sample of commercial silica gel havin a surface area of 340 m. /g. and a pore volume of 1.15 cc./g. (Davison grade 59 silica) was contacted with a solution of 1.6 g. of titanium tetrachloride in 50 ml. of water containing 5 grams of oxalic acid. The impregnated silica gel was dried at a temperature of 100 C. and then calcined at a temperature of 800 C. for 2 hours to produce a titania/silica product.

A 35 gram sample of this catalyst Was then contacted with 20 mls. of chlorotrimethyl silane as vapor for 15 hours at 325-350 C. This silylation was repeated twice. The resulting catalysts (both silylated and unsilylated) were compared. Analysis showed that each contained 1.0% by weight titanium. The silylated catalyst was hydrophobic, while the unsilylated catalyst was hydrophilic.

B. The epoxidation of propylene with ethylbenzenehydroperoxide was conducted in a 0.43 inch internal diameter 20 inches long fixed bed tubular reactor packed with 20 grams of the silylated silica-titania catalyst of part A. This experiment was repeated with the catalyst of part A, unsilylated. A reaction mixture consisting of 6 moles of propylene per mole of ethylbenzene hydroperoxide in ethylbenzene was continuously fed to the reactor, maintained at the indicated temperature and a pressure of 450 p.s.i.g., at a rate giving a residence time of 24 minutes. The reaction conditions and analysis of the product mixture after the indicated reaction time are provided in Table V.

C. The silylated titania-silica product of part A was tested as octene-1 epoxidation catalyst. In this test a 1 gram sample of catalyst was contacted with 36.5 g. of octene-1 and 4.5 of 98% tertiary-butylhydroperoxide in a 100 ml. glass reactor. The reaction temperature was 101103 C. After 1 hour, 73% of the hydroperoxide was converted (with 99% selectivity to octene oxide) and after 3 hours 90% was converted (also with 99% selectivity).

Example IV A. A 300 gram batch of calcined, unsilylated, 1.5% by weight titanium catalyst was prepared as described in part A of Example I. A 250 gram sample of this catalyst was then contacted with 50 mls. of dichlorodimethylsilane as vapor for hours at 350 C.

B. The silylated and unsilylated products of part A were comparatively tested as olefin epoxidation catalyst. In each test a 1 gram sample of catalyst was contacted with 17 g. of octene-1 and 28.6 g. of a 12% by weight solution of ethylbenzene hydroperoxide in ethylbenzene in a 100 ml. glass reactor. The reaction temperature was 100 C. and the reaction time was 1 hour. The results of these tests are given in Table VI.

TABLE VI Hydroperoxide Epoxide conversion, selectivity, percent percent Catalyst:

Unsilylated 1.5% wt. titanium 95 79 silylated with (CH3) 2SiCl2- 87 89 Silylated with (CHahSlCl... 95 91 Example V Example VI A 1.5 by weight titanium-on-silica catalyst was prepared by treating an acidic silica hydrogel with a titanium salt solution, adding base to the mixture, drying and then calcining.

A sample of this catalyst .was then treated with trimethylchlorosilane in benzene at 60-70 C. for two hours and dried at 150 C. for 2 hours.

A single sample of silylated material was then repeatedly used as a catalyst for the batch epoxidation of octene-1 with ethylbenzene hydroperoxide using the apparatus, feeds and conditions of Example 1, part B. The results of the repeated 1 hour tests are given in Table VII.

Example VII A. A 1480 gram batch of the commercial silica gel (Davison I.D. grade silica 14-30 mesh) was contacted with a solution of 130 grams of tetraisopropyltitanate and 97 grams of acetylacetone in 1.25 liters of isopropyl alcohol. The impregnated silica gel was charged to an electrically heated calcination tube and dried to a bed temperature of 500 C. under a nitrogen blanket. Air was then admitted and the temperature was raised to 800 C. and there held for four hours to burn ofI' residual carbon and thoroughly chemically combine the silica and titania. 1183 Grams of this material was then rehydrated by contact with steam at 400 C. for 3 hours. This rehydrated material was cooled to 200 C. then contacted with hexa- TA-B LE VIII Hydroperoxlde Epoxide conversion, selectivity, percent percent atalyst:

Unsilylated. 72 Silylated 95 93 I cl aim as my invention:

1. The process for increasing the olefin epoxide selectivity of an olefin epoxidation catalyst consisting essentially of an inorganic siliceous solid containing an oxide or hydroxide of a metal'selected from the group consisting of titanium, molybdenum, zirconium, vanadium and boron, which comprises reacting said catalyst for a time period of from 0.1 to 48 hours, at a temperature from about100 C., to about 450 C., with an organic silylating agent selected from the group consisting of (a) trihalo-monohydrocarbylsilanes, dihalo-dihydrocarbylsilanes and monohalo-trihydrocarbylsilanes wherein the halo substituents are selected from the group consisting of chloro, bromo, and iodo and the hydrocarbyl substituents each have from 1 to 4 carbon atoms, and (b) organodisilazanes having the structural formula wherein 4 or 6 of the Rs independently are lower alkyls of from 1 through 4 carbon atoms and the other Rs independently are hydrogens.

2. A catalyst for the epoxidation of olefinically uusat-.

ceous solid and an oxide or hydroxide of a metal selected from the group consisting of titanium, molybdenum, zirconium, vanadium, and boron for a time period of from 0.1 to 48 hours, at a temperature from about 100 C. to about 450 C., with an organic silylating agent selected from the group consisting of (a) trihalo-monohydrocarbylsilanes, dihalo-dihydrocarbylsilaues and monohalo-trihydrocarbylsilanes wherein the halo substituents are selected from the group consisting of chloro, bromo, and iodo and the hydrocarbyl substituents each have from 1 to 4 carbon atoms, and (b) organodisilazanes having the structural formula wherein 4 or 6 of the Rs independently are lower alkyls of from 1 through 4 carbon atoms and the other Rs independently are hydrogens.

3. The process for increasing the olefin epoxide selectivity of an olefin epoxidation catalyst consisting essentially of an inorganic siliceous solid containing an oxide or hydroxide of titanium, which process comprises reacting said catalyst with an organic silylating agent selected from the group consisting of (a) trihalo-monohydrocarbylsilanes, dihalo-dihydrocarbylsilanes and monohalo-trihydrocarbylsilanes wherein the halo substituents are selected from the group consisting of chloro, bromo, and iodo and the hydrocarbyl substituents each have from 1 to 4 carbon atoms and (b) organodisilazanes having the structural formula (Rh-Si-N-Si-(R);

wherein 4 or 6 of the Rs independently are lower alkyls of from 1 through 4 carbon atoms and the other Rs independently are hydrogens; for from 0.1 to 48 hours at a temperature of from 100 C. to about 425 C.

4. The process of claim 3 wherein the organic silylating agent is a tetra-substituted silane and wherein the reaction time is from 1 to 48 hours and the reaction temperature is from 300 C. to 450 C.

5. The process of claim 4 wherein the organic silylating agent is chlorotrimethylsilane.

6. The process of claim 3 wherein the organic silylating agent is an organodisilazane and wherein the reaction time is from 0.1 to 5 hours and the temperature is from 100 C. to 300C.

7. The process of claim 6 wherein every R is a lower alkyl of from 1 through 4 carbon atoms.

8. The process of claim 7 wherein every R is methyl.

9. A catalyst for the epoxidation of olefinically unsaturated hydrocarbons with an organic hydroperoxide, said catalyst being the product of reacting an olefin epoxidation catalyst consisting essentially of an inorganic siliceous solid containing an oxide or hydroxide of titanium with an organic silylating agent selected from the group consisting of (a) trihalo-monohydrocarbylsilanes, dihalodihydrocarbylsilanes and monohalo-trihydrocarbylsilanes wherein the halo substituents are selected from the group consisting of chloro, bromo, and iodo and the hydrocarbyl substituents each have from 1 to 4 carbon atoms and (b) organodisilazanes having the structural formula wherein 4 or 6 of the Rs independently are lower alkyls of from 1 through 4 carbon atoms and the other Rs independently are hydrogens; for from 0.1 to 48 hours at a temperature of from about 100 C. to about 450 C.

10. The catalyst of claim 9 wherein the inorganic siliceous solid contains at least 99% weight of silica and the amount of titanium oxide or hydroxide present is from about 0.2% to about 10% by weight of the total catalyst.

11. The catalyst of claim 10 containing, prior to reaction with said silylating agent, from about 0.01 to 5% by weight of calcium oxide, based on the weight of the catalyst composition.

12. The catalyst of claim 10 wherein the organic silylating agent is a tetra-substituted silane and wherein the reaction time is from 1 to 48 hours and the temperature is from about 300 C. to 425 C.

13. The catalyst of claim 12 wherein the silylating agent is chlorotrimethylsilane.

14. The catalyst of claim 10 wherein the organic silylating agent is an organodisilazane and wherein the reaction time is from 0.1 to 5 hours/ and the temperature is from C. to 300 C.

15. The catalyst of claim 14 wherein every R is methyl.

16. A catalyst for the epoxidation of olefinically unsaturated hydrocarbons with an organic hyperoxide, said catalyst being produced by reacting an olefin epoxidation catalyst consisting essentially of silica gel containing an oxide or hydroxide of titanium with hexamethyldisilazane vapor for about 1 hour at a temperature of about 200 C.

17. The process for producing an olefin epoxide catalyst of high selectivity consisting essentially of a silylated composition of an inorganic siliceous solid containing an oxide or hydroxide of titanium, which process comprises impregnating silica gel with a solution of a titanium compound, calcining the mixture, rehydrating the calcined composition and thereafter contacting the rehydrated composition for a time period of from 0.1 to 48 hours, at a temperature from about 100 C. to about 450 C., with an organic silylating agent selected from the group consisting of (a) trihalo-monohydrocarbylsilanes, dihalo-dihydrocarbylsilanes and monohalo trihydrocarbylsilanes wherein the halo substituents are selected from the group consisting of chloro, bromo, and iodo and the hydrocarbyl substituents each have from 1 to 4 carbon atoms, and (b) organodisilazanes having the structural formula (Rh-Si-N-Si-(R),

wherein 4 or 6 of the Rs independently are lower alkyls of from 1 through 4 carbon atoms and the other Rs independently are hydrogens.

18. The process of claim 17 wherein the organic silylating agent is chlorotrimethylsilane.

19. The process of claim 17 wherein the organic silylating agent is an organodisilazane.

20. The process of claim 19 wherein the organic silylating agent is hexamethyldisilazane.

21. As an epoxidation catalyst, the composition produced according to the process of claim 17.

22. As an epoxidation catalyst, the composition produced according to the process of claim 18.

23. As an epoxidation catalyst, the composition produced according to the process of claim 19.

24. As an epoxidation catalyst, the composition produced according to the process of claim 20.

References Cited UNITED STATES PATENTS 3,634,464 1/ 1972 Wulflf et al. 260-3485 L 3,351,635 11/1967 Kollar 260-3485 L 3,332,965 7/1967 Fukui et a1 260-3485 L 2,722,504 11/1955 Fleck 252-430 X 3,207,699 9/ 1965 Harding et al. 252-430 3,213,156 10/1965 Harding et al. 252-430 X 3,389,092 6/1968 Sanford et al. 252-430 PATRICK P. GARVIN, Primary Examiner US. Cl. X.R.

" gg gg UNITED STATES PATENT OFFICE CERTIFICATE OF CORRECTION Patent No. 3,829,392 Dated Aug. 13, 1974 Inventor-(s) HARALD P. WULFF It is certified that error appears in the above-identified patent and that said Letters Patent are hereby corrected as shown below:

Column .8, line 18, in table VII, the number "75" should read 73 Y In column 9, line 35, "425C" should read 450c In column 9-, line 4 0, "450C" should read 425C Signed and sealed this 4th day of March 1975. I

(SEAL) Attest:

, C. MARSHALL DAN-N RUTH C. MASON v Commissioner of Patents Attesting Officer and Trademarks 

